FINAL REPORT

SOLAR POWERED SONIC BOOM MICRO PUMPTeam D12 December, 2012

Sean MunckNam PhamNick PinnExecutive SummaryUnderdeveloped countries depend on subsistence farming for food, and many lack the resources and technology to efficiently irrigate crops. Instead, they rely on traditional methods which waste both water and energy. The Micro Turbine Pump solves this problem by providing ample water flow for drip-irrigation methods. Because the pump is solar-powered, there is no need for connection to an existing power grid. This product is intended for farmers looking to better irrigate their crops, especially in underdeveloped regions.The Sonic Boom Pump uses an in-water centrifugal impeller design to efficiently pump water. The axial inlet impeller remains efficient even in this low power micro-pump scenario. With only a 1.5 inch diameter tube extending 2 inches into the water, the Sonic Boom Pump is small enough to be used in wells. The above-water, insulated housing for the motor and other electrical components ensures durability and safety. The net present value( NPV) of our project, according to the base model is positive and we plan to proceed with development. We hope that this information will assist the client in further investment. Part of our design strategy will revolve around delivering a 1.9 liter/min flow rate as requested from the customer. Our design specs prove this to be a valid prediction. By keeping specially fabricated parts and materials to a minimum, the Sonic Boom Pump is very reasonably priced at $33.86. The reliable, cost-effective, and efficient design should be well-suited for micro-drip irrigation agriculture.Table of Contents __________________________________________________________________

Executive Summary

1. Introduction..41.1 Problem1.2 Background Information1.3 Project Planning

2. Customer Needs and Specifications.5

3. Concept Development..53.1 External Search3.2 Problem Dissection3.3 Design Concepts3.4 Concept Combination3.5 Concept Selection

4. System Level Design..8

5. Detailed Design...........85.1 Changes from Proposal5.2 Theoretical Analysis5.3 Industrial Design5.4 Material Selection5.5 Manufacture and Fabrication5.6 CAD Drawings5.7 Economic Analysis5.8 Addressing Safety

6. Prototype Testing.......136.1 Test Procedure6.2 Test Results

7. Conclusion and Recommendations.......157.1 Conclusion7.2 Design Improvements7.3 Project Experience

8. References....16

Appendices:

A. Gantt ChartB. Product SpecificationsC. Weighted Customer NeedsD. Concept GenerationE. Concept GenerationF. Patent Search ReferencesG. Concept CombinationH. Bill of MaterialsI. Dimensioned DrawingsJ. Performance Curves

1. Introduction

1.1 Problem:The goal of the project is to design a pump which can be used to provide water for drip crop irrigation. The pump system must achieve a flow rate of at least 1.9 liters per minute over an elevation change of 0.5 meters.

For this project, the team had to work within the constraints specified by Prof. Lamancusa. It had to be self-priming, and powered entirely by an unmodified solar panel. Once it began running, the pump had to operate without any user control. The system had to be insulated and protected from any danger of electrocution. Every team was provided with a choice of four motors, from which each could choose only one. This motor would not be replaced for any reason. Replicating existing parts from other pump designs was permitted. The total budget for the project was limited to $100.

1.2 Background Information:Flood irrigation is the primary method of irrigating crops in many underdeveloped regions, even though many other methods, including drip irrigation are more efficient. [1] Research on drip irrigation techniques allowed the team to design a system which satisfies the requirements of a farmer with limited knowledge of the pump and little or no access to an electrical grid. [2] It was also determined that the pump system has a relatively low flow rate and high head requirement for pumping. [3] This information helped to establish conditions for research on existing micro pump types and designs. [4]

With the planets ever-expanding need for food, an efficient and cost-effective method of irrigating crops is essential in the development of many Third World nations. Therefore, designing a successful drip irrigation pump system is a valuable investment. Existing pump research, established requirements and customer needs were combined to produce a fitting design which will succeed across the entire customer base.

1.3 Project Planning:The team used a series of given project milestones to generate a specific timeline and Gantt chart (Appendix A). Each member was given leadership roles in various project steps. Nam managed initial product research and assigned individual tasks evenly among members. Sean led concept modeling, and will be managing prototype construction. Nick headed the proposal presentation, and will be leading the design report.Our team plans to follow a set design process, involving planning, concept development, system level design, detailed design, testing and production. With this clear, step-by-step process we expect to attain better results relative to timely task completion and increased project aid from team documentation.

2. Customer Needs and SpecificationsThe primary goal of Team D is to design a solar powered micro pump for the drip irrigation of crops. The project limitations and requirements mean that the system shares many similarities with pump systems in other markets, specifically small-scale plumbing and boating (emergency water bailing). The team decided to generate customer needs from research of these established systems as well as direct interviews with a local plumbing company, GoodCo.

An interview with Chris Good, an employee of GoodCo. Plumbing yielded valuable results. The company uses micro centrifugal pumps almost exclusively for sump and sewage pump applications, as they consistently exhibited better performance/durability vs. cost when compared to positive displacement designs. Additionally, Mr. Good recommended researching battery-powered micro pumps used in the evacuation of water from flooded basements or boats.

Online customer research regarding these pumps led us to conclude that although the battery-operated pumps were very easy to install and use, many suffered from leakage issues, especially into the motor housing. Since these pumps were not self-priming, they had to be immersed in water to function, and suffered from poor build quality. US customers seemed to be willing to pay more for a pump which had better durability.

Customer input and research was condensed into seven customer needs. A needs-metrics matrix approach was used to generate product specifications for each need (Appendix B). An AHP weighting matrix was used to weight each specification, giving the team a reasonably accurate means of comparing product concepts. [5] The final list of product specifications and their weights is shown below in Table 3 (refer to Appendix C for detailed information).

NeedWeightDescription

Safety28%Product must pose no electrical or other hazard

Durability24%Product should last for 5 years of irrigation cycles

Price18%Product should be manufactured for less than $50

Ease of Use/Assembly, Disassembly12%Product components should be fully accessible, and steps should be universally understandable

Efficiency9%Pump should operate within solar power limits

Simplicity of Design8%Parts should be common and kept to a minimum

Compactness1%Product should be easily carried in one hand

Table 1. Concept Specifications and Weights

3. Concept DevelopmentResearch was done by all team members on existing irrigation pump systems and current patents to help narrow down the top concepts. Eleven designs were produced, but were reduced to the top four. A Concept scoring matrix helped the team to pick out the best design that met all of the selected product specifications.

3.1 External Search:The best-designed pump system must meet all product specifications, which were translated from the most important customers needs. The potential product must also be durable so as to withstand frequent wear and weather variation. With these points in mind, the team did external searches on the different types and designs of pumps. The abilities to self-prime and to deliver a constant flow of water with high efficiency were also high on the list of priorities. [6] Patent searches related to the top four generated design concepts were done [7-10], which are shown in Table 2 (refer to Appendix E for full patents details).The external research proved to be extremely helpful in finding different pump designs. Mixtures of centrifugal and positive displacement pump designs were presented as a result of the research. [11] Even though the majority of the current existing irrigation systems are centrifugal based, it did not limit the possible generated design concepts. There are many designs within each type and the team considered both. The abundance of designs only helped toward generating new concepts.Double Acting Piston [7]Pat. #5076769Filing date: Jul 16, 1990Issue date: Dec 31, 1991Multiple Magnetic [8]

Pat. #4678409Issued July 7, 1987Plastic Gear Housing [9]Pat. #6325604

Water Well [10]

Pat. #7837450Issued:November 23, 2010Filed:January 18, 2007

Descriptions

The piston is driven by a gear motor which acts as a double piston (double acting) sliding back and forth.This is a double magnetic pump system. It has two inlets and two outlets. A single driving shaft is connected through both chambers.This is a simple gear pump consisting of a drive gear and an idle gear. The contact points between the gears and the interior are sealed to pump water.This is a turbine pump system. The motor is submerged with a long shaft driving multiple turbine impellers. It draws low power, so it can be powered by solar panel.

Analysis

This patent provides the same functionality with less complicated parts. This could possibly replace our design of the double piston.This patent has an interesting magnetic design. Nevertheless, this may possibly need to be submerged in the water. Since it is a double pump, the motor would have to be powerful.This is a simple gear pump design. With multiple contact points, wearing of gears may prove to be a problem.This design has a lot of parts. It could possibly be hard to manufacture and assemble. Low power input is a big plus considering our power source is solar panel.

Table 2. Top Patent Search Summary

3.2 Problem Decomposition:

Water

Water Mechanical energy applied to waterConverted to electricity by solar panelLight Source

Motor converts electricity into mechanical energyTrigger opens circuitOn/Off Trigger

Heat

Figure 1. Pump System Functional Diagram

3.3 Concept Generation:Eleven concepts were generated through brainstorming and using the sticky notes process. The concepts were designed to meet at least most, if not all of the requirements. From there, the team narrowed down the concepts to the top four by voting and weighting of the pros and cons. The top concepts unanimously decided upon by the team are the double piston, floating magnetic centrifugal, gear, and turbine. For detailed models and descriptions of these concepts, refer to Appendix F.

3.4 Concept Combination:The conversions of energies are broken down to just a solar panel, and a motor. More freedom is given when discussing about applying mechanical transmission (Appendix G).

3.5 Concept Selection:Multiple concepts based on both types of pump systems undertook the design selection criteria screening. The concept scoring matrix helped with choosing the best design (Table 2, Appendix D).

The top concept proved to be the magnetic design. Through further discussion, the team disagreed with the outcome considering that a physical shaft is much more reliable and better suited to the problem than a magnetic design. The magnet may slip in situations where the resistance to spinning overcomes the strength of the magnets. Additionally, having magnets which are strong enough to provide the required torque may cause too much friction as a result of their bond. The team decided to combine the floating feature of the magnetic pump design with the second concept, the turbine. This combination will remove the needs to water-proof the sensitive parts individually, such as wiring and the motor. Water will be able to travel vertically upward as the axial impellers rotate. The finished product should be light, simple, rigid, and compact. In general, turbines do not require a lot of power and can be easily run by solar power. It also produces a constant flow of water even with the low RPM.4. System Level DesignThe team wanted to produce a safe, durable, and cost-effective micro-pump for crop drip irrigation. The finalized design utilizes PVC housing, and is placed in-water. A series of 3 axial impellers draws water up through the filter into the pump. The water is forced through an exit nozzle of much smaller diameter than the pump inlet, so as to increase exit water velocity. The section of PVC housing containing the motor and switch are insulated from the environment by a screw-on cap. All housing components are secured using PVC cement.

PVC is used for the housing because of its low cost, abundance, and ease of manufacturing. The plastic impellers are based on micro RC boat propellers, also selected with ease of replacement and cost-efficiency in mind. The motor selected is the Jameco RS-385SH. It provides the best efficiency within the operating range of our pump, and should generate the highest flow rate. The motor is connected to the impeller shaft by means of an axial adapter, maintaining 100% shaft efficiency.Flow Direction Figure 2. Current Prototype Design

5. Detailed Design5.1 Changes from ProposalAfter reviewing the proposed concept, several important changes had to be made. The position of the nozzle was changed to allow for the motor. The cap separating the impeller tube from the motor housing was reduced in size to decrease cost and required length of the pump. The diameter of the impeller tube was increased to allow for a pre-fabricated PVC grate. Insulating rubber liners were added to increase waterproofing between the motor and impellers, after it was discovered that there was some water leakage through the cap. Impeller Housing RingsRubber LinerBarbed Hose AttachmentShaft CouplerBarb Mounting TubePower SwitchEnd-Cap AdapterInlet CoverMotorSize 1.5 PipeImpeller2 to 1.5 AdapterPlastic CapRubber LinerEnd-Cap ScrewPlastic Cap

Figure 3: Exploded View of Pump5.2 Theoretical Analysis

The specification of the pump in production must be the following requirements:

Flow ()Head ()

0.51.64042

Unfortunately, the motor was chosen based on the speed and torque that it produces. Through reanalyzing the different motors speed, the motor that produced the most revolutions per minute should not have been chosen. The efficiency for the motor with the lowest speed (3000 RPM) is roughly 82%. An analysis was conducted to produce a graph of the DC motors performance at 12 volts (Appendix J Fig. 12-13).

Part no. 2125528Part no. 174693

Motor Efficiency~ 63%~ 82%

The turbine pump design proved to be ineffective and inefficient with the high speed motor and it did not meet the minimum specifications during testing. A different design (axial centrifugal) was chosen. Thus a new performance curve data was pulled for analysis. Head and flow rate values are pulled from Dr. Lamancusas Little-Giant pump analysis sample report.

Little-Giant Pump Specs

Diameter ()Speed ()

1.53250

A new generated relationship is produced to show the different curves of head versus flow operating at a variety of speeds. The following affinity laws helped with the iterations of these curves:

A new pump diameter of 1.0 and 1.5 are compared to the existing centrifugal pump 1.5 diameter. The iterations produced three equivalent head versus flow rate relationships operating at 2400, 2800, and 2950 RPM for the slower motor, and at 8170, 6400, 400 RPMs for the bigger motor.

A system load relationship is then produced to find the operating torque. The system load shows the correlation between the total head at flow rate ranges from 0 to 16 GPM. The intersection between the system load and the equivalent performance curves (Appendix J Fig. 14-17) enable the team to find the equivalent motor torque at certain voltages (12V, 10V, 7.5V, 5V) using the following properties and equations:Specific Gravity of H2O ()62.4

Pump Efficiency 0.7

()66.67

.0633

.001899

,*Hand-calculations and a quadratic solver are used to find the intersection points between the curves. The numbers represents the data from the smaller motor with a 1 inch Dia. impeller.

()2577.732530.32471.012411.73

()32.6325.6216.878.113

()269.94264.97258.76252.56

The total torque lost () can also be related to the torque loss ( ), and the torque constant ():,

Relates the equations to find current,

Power to Motor

VoltageCurrent ()

120.55

100.43

7.50.30

50.16

Relates the power to motor data to the solar panel output and check where it intersects. This intersection represents the operating point of the pump (Appendix J Fig. 18-21).

Operating Point @ 3K RPM MotorVoltage ()Current ()Power Input to Motor ()Head Flow Rate PerformanceEfficiency

@ 1 DIA. 8.920.3793.3811.920.656~72%

@ 1.5 DIA.8.950.3913.4993.601.73~81%

Operating Point @ 10K RPM MotorVoltage ()Current ()Power Input to Motor ()Head Flow Rate Performance Efficiency

@ 1 DIA. 4.220.4581.9331.880.598~28%

@ 1.5 DIA.4.10.4621.8955.7152.49~26%

The above results demonstrate that the higher speed, 10,000 RPM, motor is extremely inefficient in performance. The smaller, and lower speed 3,000 RPM motor performance efficiency is extremely high. There is an inverse relationship between the two motors. The faster motor efficiency increases as the impeller diameter decreases. The slower motor efficiency decreases as the impeller diameter increases.

It would be the teams best interest to go with the smaller motor due to its high performance efficiency. The data shows that all impeller sizes, at both motors, will provide sufficient head and flow rate.

The best motor will be the Part no. 174693, operating at 3000 RPM.The best impeller size will be at 1.5 inch diameter.

*These calculations have been verified by testing the data points from the sample report Little Giant Pump. The results turned out to be relatively the same.

5.3 Industrial DesignThe Sonic Boom Pump is sturdy, compact, and offers a pleasing design. It is easy for users to hold and operate. The clear plastic inlet cover protects the impeller from debris, while also providing an efficient means of drawing water. The screw-on cover ensures a waterproof seal to insulate the motor and allows for users to easily access all electrical components. The pump includes a hose which is easy to attach. The durable housing is assembled using PVC cement, creating a single, piece. The foam floats around the body of the pump allow it maintain a steady flow rate as water levels change, while also keeping electrical components from being submerged. The wires leading to the PV panel are also well insulated, ensuring safe operation. 5.4 Material SelectionThe housing for the Sonic Boom Pump will be assembled from Schedule 40 PVC pipe and fittings. Using standard-size PVC components eliminates costs for injection molding, and creates a housing which is very cost-effective for its durability and ease of assembly. The pump is designed for Third World agricultural use. Pleasing colors and designs are less important than a product which feels tough. The impellers will be injection-molded out of Polyetheretherketone, a type of plastic commonly used for pump impellers due to its thermal stability, abrasion resistance and low moisture absorption. This will reduce costs and manufacturing time, while still providing adequate strength and performance. 5.5 Manufacture and FabricationFabrication of the Sonic Boom Pump combines ease of assembly with low cost. Wholesale PVC orders are very cost-effective, and the majority of components will be cut from longer pipe sections. PVC cement will be used to permanently assemble the housing, fusing it into one piece. The 2 to 1.5 adapter and the barb mounting tube will be injection-molded as one piece. The impeller will be injection-molded, as purchasing pre-fabricated impellers becomes more expensive with a production run of 100,000 units. The impeller housing rings will be permanently attached to the inlet cover. The impeller shaft will be cut from pre-fabricated brass wire. All electrical components (switch, wire, motor) will be ordered to avoid fabrication costs. 5.6 CAD DrawingsThe Sonic Boom Pump is constructed out of 17 separate components, many of which are purchased off-the-shelf. Components which must be injection molded or modified during manufacture are detailed in Appendix I. A detailed exploded view showing all parts is shown in Section 5.1.

5.7 Economic AnalysisBecause so many of the parts used were easily available in hardware stores and online, calculating the majority of expected costs was quite easy. The cost of the PVC segments and caps was based on online wholesale rates, and the cost of injection molding the impellers was calculated from the raw material cost. Net Present Value (NPV) analysis was performed on the Sonic Boom Pump over the first four years of production, based on researched analysis guidelines [5]. Based on the NPV analysis, the product is expected to be profitable by the 2nd year. By the 4th year, the product expected revenue should be around 4.1 million dollars. For more information, see Appendix H.

Table 3. Bill of Materials5.8 Addressing SafetyAs shown by Weighted Customer Needs (see Appendix C), safety is of primary importance to users. The Micro Turbine Pump addresses primary concerns, such as electrical hazards and the dangers of the spinning impellers. The well insulated and waterproofed housing protects electrical components and floats keep them above water. A sturdy grate prevents damage to the blades and to users. The pump is intended for adult users, but is safe for those over the age of 10. Production of The Micro Turbine Pump does not involve any chemicals which may be hazardous to users or to the water used in irrigation. Drop-testing of the pump demonstrates its durability in field use. In the event of impeller blade failure, the grate may be removed to install a new blade shaft. We plan to protect the motor and electrical components from water damage using a thin-walled rubber sheet which is designed to completely insulate the device. Safety is our highest concern, and we made sure our pump passed all ULxxx and IECxxx Safety requirements. 6. Prototype Testing6.1 Test ProcedureName of PrototypeMicro Turbine Pump Floatation/Impact Test

PurposesSelect material for floats

Confirm suitability of PVC housing for floatation

Confirm housings durability

Level of ApproximationCorrect housing dimensions

Correct weight

Experimental PlanPlace prototype in water tank, observing any leakage points and relative buoyancy

Note any points of weakness

Drop prototype onto concrete floor from standing height of 5 ft.

Observe damage to prototype

ScheduleNovember 5Complete Alpha Prototype

November 7Perform floatation test

November 14Perform impact test

November 15Analyze test results

In order to present the most efficient design, it is important to develop an alpha prototype as well as a way to test the model. In developing our pump we tested turbine speed vs. torque, motor speed vs. Torque and the combine system output. The power of the motor relative to the energy produced by the power source and the impeller size were biggest factors in our test results.For experimental testing we attached our motor to the solar panel and a voltmeter to observe our predicted calculations for current and voltage to the device. We were able to calculate the predicted power of the system mathematically multiplying the RPM (speed) of the motor by the torque. As a result of centrifugal pump research, we were a able to observe our specs verses similar devices in the same size category. Considering our pump will be in the water, water proofing the internal motor and electric components will be one of our top priorities. It is important to understand how the device will float or sink in water to determine how to make the right changes to our final design. Initially, the device sank during our float test and we had to devise a plan to increase buoyancy. We decided to add a foam floatation device around the outer shell to keep the device afloat. Test instructions: 1.Connect the wires between the solar panel, and pump motor2.Turn on the light source (Can use the voltmeter to measure voltage/current of the circuit3.Submerge pump in water tank4.Set tanks 0.5m apart5.Turn on pump (Observe flow, head, flow rate)Experiment Materials:1.Voltmeter2.Pump3.wire clamps4.Two Water Tanks 21x33x18 cm6.2 Test ResultsThe data from our floatation test showed that while the foam does provide enough buoyancy, it was a bit cumbersome. It was concluded that the foam should be replaced with an air-filled floatation device. The results of the impact test were very positive. Every component remained unharmed, and the PVC housing proved to be a durable design. Because these tests were observational, no quantitative data could be gathered. The most recent test performed examined the motors performance within the housing when run from the PV panel. This test was also successful, but only after the amount of insulation between the motor and shaft was reduced. This calls for a redesign of the waterproofing method.Based on the flow rate test, the turbine pump design did not meet the project required specifications. The pump only achieved about 4 inches of head and insufficient flow rate. Further analysis revealed that the axial turbine design would not provide enough head and flow rate within the limitation of the motor (Part no. 2125528). As a result, the design needed to be change.The turbine axial design was altered into an axial centrifugal design. Consequently, the new centrifugal design did meet the project required specifications.The first test was performed by placing the pump in a bucket filled with water. The pump was turned on, and the outlet tube was slowly raised vertically until water stopped flowing from the outlet. This is where the maximum head was measured.The flow-rate test was performed by again placing the pump in the water bucket. This time, the head was set at a fixed height, and the pump was turned on. Water flowing from the outlet tube was collected in a 1 liter beaker, and the time taken to fill the beaker was measured.Results gathered from the two designs:Design TypeFlow ()Head ()

TurbineInsufficient~ 0.333

Axial Centrifugal0.647~ 1.70

*Based on the competition performance, our new design pump failed to perform. Significant water leakage was observed during the performance. As a result, the motor were completely overflowed with water. Our waterproofing method failed to deliver. Another flow rate test was performed in the aftermath of the leakage:Flow ()Head ()

~ 2.0~ 0.5

Insufficient~ 1.64 (minimum specification)

Once again, this calls for a redesign of the waterproofing technique.7. Conclusion and Recommendations7.1 ConclusionProgress on the Sonic Boom Pump has completed final beta prototype development and testing. Several major changes were made to the final prototype as a result of initial beta testing. The purely axial impeller design provided inadequate head for the required application. The housing of the pump proved to be durable, but several issues were discovered with sealing the motor shaft. Further development of this prototype is required to ensure that the Sonic Boom Pump is safe and reliable for users. The Sonic Boom Pump has an ergonomic design, and is no bigger than a portable flashlight. Although it is a design primarily inspired by practicality, the pump has a pleasing shape, size and feel. Continued support in the Sonic Boom Pump would be of great value to the team and to customers. The amount of useful research, prototyping and testing will support a successful final pump design, providing farmers in the Third World with much needed improvement in irrigation.

7.2 Design ImprovementsThe biggest improvement made to the final beta prototype was a redesign on the impeller. Axial impellers, which displayed inadequate head, were replaced with a single centrifugal impeller. In initial testing, both head and flow specifications were dramatically improved. Ultimately though, the beta design proved to be unsuccessful in its reliability. Performance that was initially up to requirements dropped when water leaked into the motor through the rubber seal. Improving the seal around the motor shaft is the biggest change which will need to be made further prototypes. Theoretical analysis of motor performance also revealed that the current motor should be replaced with a smaller, more efficient motor to improve performance. Although several very important changes need to be made to the current design, the knowledge gained from current prototypes is very valuable, and a very important step in the design process.

7.3 Project ExperienceThe Solar Pump Project was very valuable in all team members understanding of the design process, from the importance of customer research, to concept development and testing, to starting over on a dead-end design. The steps involved in creating a successful product can feel slow and overly-detailed, but each is very important. The values and challenges of working as part of a team were perhaps some of the most important lessons learned this semester. Those same struggles exist in the working world, and are instrumental in becoming a successful engineer. This project was the first time several team members really felt like engineers.

7. References1) "Flood Irrigation Introduction." Alliance for Water Efficiency. Alliance for Water Efficiency, 2010. Web. 22 Sep 2012.

2) Brunet, Edward. "Pumps - Centrifugal vs. Positive Displacement." PHDEngineer. N.p., n.d. Web. 20 Sep 2012.

3) Cengel, Yunus A., and John M. Cimbala. Fluid Mechanics: Fundamentals and Applications. Boston: McGraw-Hill Higher Education, 2010. Print.

4) Dee, James. "Different Pumps for Irrigation Systems." Government of Western Australia Dept. of Agriculture and Food. Western Australia Agriculture Authority, 2011. Web. 22 Sep 2012.

5) Ulrich, Karl T., and Steven D. Eppinger. Product Design and Development. New York: McGraw-Hill Higher Education, 2011. Print.

6) Morales, Teresa, and John Busch. Oregon. "Natural Resources Conservation Service". Design of Small Photovoltaic Solar-Powered Water Pump Systems. Washington, DC: United States Department of Agriculture, 2010. Print.

7) Shao, Jian-Dong. Double Acting Pump. U.S. Patent 5076769. Filed Jul 16, 1990. Issued Dec 31, 1991

8) Kurokawa, Toshio. Multiple Magnetic Pump System. U.S. Patent 4678409. Filed Nov 21, 1985. Issued Jul 7, 1987

9) Du, Benjamin. Plastic Gear Pump Housing. U.S. Patent 6325604. Filed Mar 29, 2000. Issued Dec 4, 2001

10) Moreland, Jerry. Water Well Pump. U.S. Patent 7837450. Filed Jan 18, 2007. Issued Nov 23, 2010

11) "SX 330 30 Watt Photovoltaic Module." bpsolar.com. BP Solar, Jun 2007. Web. 1 Oct 2012.

12) Chavez, J.L., D. Reich, J.C. Loftis, and D.L. Miles. "Irrigation Pumping Plant Efficiency." Colorado State University Extension. 4.712 (2011): Print.

13) "VT Series - Vertical Turbine Pumps 60Hz Performance Curves." Taco-HVAC. Taco, Inc., 25 2009. Web. 27 Nov 2012.

Appendix A. Gantt Chart

Appendix B Product Specifications

Appendix C Weighted Customer Needs

Appendix D Concept Generation

Appendix E Concept Generation

Figure 1. Double Piston PumpDescription: The two pistons are driven by a single motor in the middle. As the disk rotates, it pushes the pistons back and forth. It creates suction in one side and pumps on the other. This pump generates a pulse-free flow and self-priming. Unfortunately it has a high number of parts.

Figure 2. Magnetic PumpDescription: This is a simple centrifugal pump. However, the driving shaft is not directly connected to the impeller. The impeller is magnetically coupled to the motor. The two tubes on the side serve as floats. It is an interesting design, but the magnetic field could be slower than direct contact by a shaft if resistance in the system overcomes the magnetic bond.

Figure 3. Gear PumpDescription: The driving gear is attached to the motor and is in contact with the idler gear. The motor powers the driving gear, of which would drive the idler gear as it rotates. The design is simple and self-priming, but the manufacturing of the housing to fit closely to the gear teeth may be difficult. With multiple contact points, there is a high potential of wear.

Figure 4. Turbine PumpDescription: This is a simple turbine pump design. A long shaft with multiple impellers is connected to the motor (at bottom in gray). The number of impellers may be reduced during manufacturing, based on which numbers produce maximum efficiency. The RPM is low for turbine, but it provides a constant and reliable flow.Appendix F: Patent Search ReferencesPatent 1: Double Acting Pump

Patent 2: Multiple Magnetic Pump System

Patent 3: Plastic Gear Pump Housing

Patent 4: Water Well Pump

Appendix G: Concept Combination

Figure 5. Pump System Concept Classification Tree (The top 4 concepts are highlighted)

Figure 6. Pump System Concept Combination DiagramAppendix H: NPV Analysis

Appendix I: Detailed Drawings

Figure 7. Dimensioned Drawing of Impeller

Figure 8. Dimensioned Drawing of Impeller Housing

Figure 9. Dimensioned Drawing of Screw-Cap

Figure 10. Dimensioned Drawing of Outer Impeller Housing Ring

Figure 11. Dimensioned Drawing of Inner Impeller Housing Ring

Appendix J: Performance Curves

Figure 12. Jamco Part no. 2125528 DC Motor Performance @ 12V

Figure 13. Jamco Part no. 174693 DC Motor Performance @ 12V

Figure 14. Motor (Part no. 2125528) Output Vs. Pump Input Power @ 1.5" Dia.

Figure 15. Motor (Part no. 2125528) Output Vs. Pump Input Power @ 1.5" Dia.

Figure 16. Motor (Part no. 174693) Output Vs. Pump Input Power @ 1.0" Dia.

Figure 17. Motor (Part no. 174693) Output Vs. Pump Input Power @ 1.5" Dia.

Figure 18. BP SX330 Panel Output Vs. Motor (Part no. 2125528) Input Power @ 1.0" Dia.

Figure 19. BP SX330 Panel Output Vs. Motor (Part no. 2125528) Input Power @ 1.5" Dia.

Figure 20. BP SX330 Panel Output Vs. Motor (Part no. 174693) Input Power @ 1.0" Dia.

Figure 21. BP SX330 Panel Output Vs. Motor (Part no. 174693) Input Power @ 1.5" Dia.

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